Adhesive constructions; and, methods

ABSTRACT

Adhesive constructions are provided. In general, the adhesive constructions include first and second fields pressure sensitive adhesive. The amount of adhesive or coverage of adhesive in the two fields differs to advantage. A particular preferred adhesive construction is provided which includes a flexible substrate defining an outer perimeter edge and having on a side thereof an adhesive pattern which includes at least two adhesive fields, preferably arranged as: an outer perimeter adhesive field adjacent to the outer perimeter edge; and an inner adhesive field spaced from the outer perimeter edge and completely surrounded by the outer perimeter adhesive field. The preferred outer perimeter adhesive field is a discontinuous pattern of adhesive with adhesive covering no more than 80% of an area of a portion of the side of the flexible substrate defined by the outer perimeter adhesive field; and, the preferred inner adhesive field has adhesive covering at least 90% of an area of a portion of the side of the flexible substrate defined by the inner adhesive field, preferably in a continuous pattern. In typical preferred adhesive constructions, the inner adhesive field surrounds an adhesive-free region. Also provided are a preferred roll stock with such an adhesive construction secured to it, and preferred methods for constructing such arrangements.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. patent applicationSer. No. 09/822,623, filed Mar. 30, 2001, issued as U.S. Pat. No.6,730,396 on May 4, 2004, which application is incorporated herein byreference.

FIELD OF THE INVENTION

[0002] The present invention relates to adhesive constructions andmethods for manufacturing and using such constructions. In preferredapplications, the invention particularly concerns adhesive constructionsfrom which a label, cover or other adhesive component, can be appliedfrom a release liner, in an effective and convenient manner.

BACKGROUND OF THE INVENTION

[0003] In general, in many industries adhesive constructions are appliedusing high speed dispensing equipment, from a roll of individualconstructions. The roll generally comprises individual elements in aline or column, adhered to a release liner. During an applicationprocess, the adhesive constructions or elements are sequentiallystripped from the release liner and are applied to a package or othersubstrate on which such a construction is desired. Arrangements of thistype are described, for example, in U.S. Pat. Nos. 5,351,426 and4,661,189, the complete disclosures of which are incorporated herein byreference.

[0004] Adhesive constructions can be used in a variety of applications.For example, they may be used as labels or as covers. In other instancesthey may be used as components in larger systems, for example as a layerin a laminate.

SUMMARY OF THE INVENTION

[0005] An adhesive construction is provided. The adhesive constructioninvolves a flexible substrate having a selected adhesive pattern, ofpressure sensitive adhesive, on at least one side thereof. The selectedadhesive pattern of pressure sensitive adhesive preferably includes atleast a first adhesive field and a second adhesive field. In preferredconstructions: the first adhesive field is a discontinuous pattern ofadhesive with adhesive covering no more than 80% of an area of theportion of the first side of the flexible substrate defined by the firstadhesive field, the area of that portion of the first side of theflexible substrate defined by the 80% adhesive field preferably being atleast 10 square millimeters (sq. mm.), typically at least 30 sq. mm.;and, the second adhesive field preferably covers at least 80% (typicallyat least 90%) of an area of a portion of the first side of the flexiblesubstrate defined by the second adhesive field; the area of the portionof the first side of the flexible substrate defined by the secondadhesive field being at least 10 sq. mm., typically at least 30 sq. mm.Preferably there is more adhesive and more surface coverage, per unitarea, in the second adhesive field than in the first adhesive field.

[0006] Adhesive constructions as defined herein may have still furtheradhesive fields thereon, as long as (preferably) the first and secondadhesive fields are present.

[0007] In preferred adhesive constructions according to the presentinvention, the first and second portions of the selected adhesivepattern are preferably defined (respectively) by an outer perimeteradhesive field; and, an inner adhesive field. The preferred outerperimeter adhesive field is arranged along (or to border) a perimeteredge or edge portion of the flexible substrate. In such preferredembodiments, the inner adhesive field is completely surrounded orcircumscribed by the outer perimeter adhesive field. In general, asdescribed above, there is a higher amount of adhesive or higher coverageof flexible substrate surface by adhesive, in the region of the inneradhesive field, than in the region of the outer perimeter adhesivefield. Preferred arrangements and amounts of coverage, are described.

[0008] In certain preferred arrangements, there is also provided anadhesive-free region on the flexible substrate. Preferably theadhesive-free region comprises an inner adhesive-free region completelysurrounded or circumscribed by an inner (or second) adhesive field. Inselected embodiments, the adhesive-free region is substantiallytransparent.

[0009] The adhesive construction will typically include, during aportion of its life prior to application to a package or othersubstrate, a release liner secured to the flexible substrate with thedefined adhesive fields therebetween. The release liner generally wouldcomprise a silicone release layer, to facilitate the separation of therelease liner from the flexible substrate, during a labeling or coveringoperation, i.e., an application process, so that the flexible substratecould then be adhered to an appropriate package or other substrate.

[0010] Methods of preparing preferred adhesive constructions accordingto the present invention are provided. In general, the methods include:applying adhesive to create the different pressure sensitive adhesivefields defined; and, conducting appropriate die cutting and wastematerial stripping operations to achieve the generation of theindividual adhesive constructions secured to a common release liner. Ingeneral, preferred die cutting operations will be conducted such thatdie cutting: is through a layer of laminate which will eventually becomethe flexible substrate of the adhesive construction; and, is in overlaponly with adhesive in the first type of adhesive field, and thus in apattern surrounding or circumscribing adhesive in the second type ofadhesive field.

[0011] Preferred methods include applying adhesive to create a first,(for example outer perimeter) adhesive field and a second (for exampleinner) adhesive field by utilizing a printing approach, typically a dotscreen printing approach, in which more adhesive is applied to theregion that will become the second (inner) adhesive field than isapplied to the region which will become the first (outer) perimeteradhesive field. This can be accomplished for example, by varying thenumber of dots or weight (wt.) of adhesive per unit area.

[0012] In typical manufacturing operations, a two layer laminate isprepared comprising two flexible webs secured to one another byadhesive. One of the flexible webs would comprise a release liner layer,and the other would comprise a flexible substrate web or layer that,when die cut, would form the flexible substrates of individual adhesiveconstructions for generation of the preferred constructions ascharacterized. The adhesive pattern between the two webs would typicallyhave two regions: a region of adhesive in a concentration that, after adie cutting operation, would form the first (outer) perimeter adhesivefield; and, a region of higher adhesive concentration which, after thedie cutting operation, would form the second (inner) adhesive field. Inpreferred constructions, the adhesive fields of the laminate areorganized such that during a die cutting operation, die cutting of theflexible substrate web only occurs in overlap with regions of loweradhesive concentration.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a schematic plan view of an adhesive constructionaccording to the present invention; the view of FIG. 1 being toward aside having adhesive thereon.

[0014]FIG. 2 is a schematic, fragmentary, plan view of a continuous rollof adhesive constructions in accord with FIG. 1 secured to releaseliner; the roll of FIG. 2 being useable in a process to apply adhesiveconstructions according to FIG. 1 to various substrates.

[0015]FIG. 3 is a schematic, fragmentary, plan view of a laminate rollstock from which a continuous roll in accord with FIG. 2 can beprepared; FIG. 3 being taken of a side having thereon a transparentflexible web from which individual adhesive constructions will be diecut.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0016] Referring to FIG. 1, reference no. 1 depicts an adhesiveconstruction according to the present invention. In general, adhesiveconstructions 1 according to the present invention may be applied topackages or other substrates, for example as labels, covers or othercomponents, depending upon the particular application. When utilized asa label, typically printed matter or graphic matter will have beenapplied to the adhesive construction 1. The adhesive construction 1would then be applied to a container or other substrate as a means ofadhering the printed matter in place, as a label. When used as a cover,the adhesive construction 1 may or may not contain printing or graphics,but in general would be applied over a portion of a substrate for whichcoverage is desired. Such a portion of substrate may be, for example, anaperture or hole, i.e., window; or, it may be printing material or othermaterial which is desired to have covered and protected. It is foreseenthat in many preferred applications, adhesive constructions 1 accordingto the present invention will be applied as substantially transparentwindows over an aperture or substrate, for example, over a hole in apackage box. By “substantially transparent” in this context, it is meantthat adequate light passes through the flexible substrate under normalviewing conditions, so that items can be readily viewed through theadhesive-free region of the flexible substrate. Of course, there is norequirement that the flexible substrate be substantially transparent,for many of the benefits of the present invention to be obtained.

[0017] As indicated above, the adhesive constructions may be used asother components and systems. For example, medical systems may involveuse of such arrangements to adhere a component of a medical system inplace. In addition, the arrangements may be utilized in shields or ascomponents in laminates, or in other manners as components in mechanicalor electrical systems.

[0018] Still referring to FIG. 1, the preferred adhesive construction 1depicted comprises a transparent flexible substrate 5 having a firstside 6 (facing the viewer) and an opposite second side 6 (directed awayfrom the viewer). For the particular arrangement shown, the first side 6has adhesive 8 applied thereto, as described below, for securing theadhesive construction 1 in place, during use. The opposite side 7 istypically adhesive-free, although such is not required for allapplications. Side 6 will sometimes be referred to as the adhesive sideof the substrate 5, or of the adhesive construction 1.

[0019] As indicated above, in general adhesive constructions accordingto the present invention are utilized by removal from a release linerand application to a package or other substrate. The adhesiveconstruction 1, FIG. 1, is depicted after removal of the release liner.

[0020] In general, the materials selected will involve use of anadhesive 8 which is, typically, a pressure sensitive adhesive, i.e.,secures upon contact and pressure. The material chosen for the flexiblesubstrate 5 will generally be one which is adequately strong or tough toallow for the manipulations required during an application process, andto remain in place for the intended use. Some usable materials arecharacterized below.

[0021] Referring still to FIG. 1, the flexible substrate 5 of adhesiveconstruction 1 generally defines an outer perimeter edge 10. For theparticular adhesive construction 1 depicted, the outer perimeter edge 10defines a quadrilateral shape, in particular a parallelogram. Theparticular adhesive construction 1 depicted is rectangular. It is noted,however, that principles according to the present invention can beutilized in accord with adhesive constructions having a variety of outerperimeter configurations, including for example those having irregularshapes, circular shapes, square shapes, triangular shapes, etc.

[0022] Still referring to FIG. 1, the adhesive construction 1 includesat least two different adhesive fields (or regions of adhesive) on theadhesive or first side 6. The two different adhesive fields 11, 12comprise: a first adhesive field 11 and, a second adhesive field 12. Itis noted that other adhesive fields different from adhesive fields 11 or12 could also be provided in the arrangement 1, provided at least thefirst and second adhesive fields 11, 12, preferably as defined, areprovided. In general, the first adhesive field 11 comprises an adhesivefield defining an area of the substrate 5 on which there is no more than80% coverage by the adhesive, preferably in a discontinuous pattern.Preferably the second adhesive field 12 is an adhesive field position tocover a selected area of the substrate, wherein there is at least 80%adhesive coverage, typically at least 90%, preferably at least 95%, andmost preferably at least 99.5%. Most preferably the adhesive in thesecond adhesive field 12 is applied in a continuous pattern. Preferablythe amount of adhesive coverage in the first field 11 is less than inthe second field, in terms of wt. per unit area; and, preferably each ofthe first and second fields 11, 12 is in a pattern having a perimetercovering at least 10 sq. mm., typically at least 30 sq. mm., of thesubstrate 5.

[0023] While the characterizations in the previous paragraph aregeneral, for adhesive fields according to the present invention, for theparticular preferred arrangements depicted the first adhesive field 11and the second adhesive field 12 are provided in preferredconfigurations, to achieve selected advantages. In particular, for thearrangement depicted in FIG. 1, the first adhesive field 11 comprises aperimeter adhesive field 13 and, the second adhesive field 12 comprisesan internal adhesive field 14. In general, the preferred perimeteradhesive field 13 is configured with the following characteristics: itborders the outer perimeter 10 along at least one side and preferablyentirely around the adhesive construction 1; and, it preferablycompletely surrounds or circumscribes the internal adhesive field 14.The particular preferred adhesive field 13 depicted, has theconfiguration of a rectangular frame 15 having a constant width andhaving, as its outside edge 13 a, the outer perimeter 10, and having asits inside edge 13 b, an interface or border with the internal adhesivefield 14.

[0024] The particular, preferred, internal adhesive field 14 depicted,circumscribes or surrounds central region 17, in which there is noadhesive. That is, region 17 is, in preferred embodiments,adhesive-free. The particular preferred internal adhesive field 14depicted is in the form of a rectangular frame 16 of constant width,having as its outer border 16 a an interface or border with inner border13 b of adhesive field 13; and, having as its inner border 16 b, aborder surrounding an adhesive-free region described below. It isforeseen that internal fields 14 having a frame configuration 16 will beused in preferred embodiments, however, alternatives are applicable withprinciples according to the present invention.

[0025] Still referring to FIG. 1, a characteristic of the preferredperimeter adhesive field 13 is that within the field 13, adhesivecoverage on the flexible substrate ranges between about 30% and 80% ofthe surface (or area) of the flexible substrate 5 covered or defined bythe perimeter adhesive field 13. That is, at least 30% of the surface ofthe first side 6 of the flexible substrate 5, (in the region defined byborders 13 a, 13 b of the perimeter field 13) is covered by adhesive,and preferably not more than about 80% is so covered. Most preferablythe coverage is no greater than 70%. Another characteristic of thepreferred perimeter field is that it has a width, i.e., dimension ofextension inwardly from the outer perimeter edge 10, indicated bydimension A, of at least 0.8 millimeters (mm.), and typically at least 1mm. and up to 5 mm.

[0026] In preferred embodiments, the adhesive pattern in the perimeteradhesive field 13 is discontinuous. By “discontinuous” in this context,it is meant that the pattern comprises a plurality of spaced adhesivespots, islands or regions 13 c, each of which is surrounded byadhesive-free region, as opposed to a continuous pattern in which thereare no readily identifiable spaced spots, regions or islands ofadhesive.

[0027] Another preferred characteristic of the perimeter field 13, isthat immediately along the adhesive construction outer perimeter edge10, the perimeter field 13 does not include an extension of more than 15mm., preferably not more than 8mm., and most preferably not more than 5mm. without the edge 10 having intersected a region, spot or island ofadhesive. That is, there is no substantial extension of edge 10, onsurface 6, which is completely adhesive-free. Alternately stated,adhesive in the region of perimeter adhesive field 13 is applied in adiscontinuous dot, spot or island pattern, with the dots (spots orislands) having been deformed or squished as a result of a laminateconstruction method used to prepare construction 1. Preferably, the dotpattern is such that the edge 10 encounters the adhesive dots ordeformed dots (spots or islands) often enough so that along the edgethere is no extension greater than about 15 mm., preferably not morethan 8 mm., (most preferably not more than 5 mm. and typically less)over which an adhesive dot (spot or island) is not encountered orintersected.

[0028] In general, the typical arrangement of adhesive application willbe applying the adhesive dots from a screen printing process. A typicalsuch process would use about a 50 line screen (i.e. a screen of 50 linesper inch in each direction). Different adhesive patterns or amounts canbe applied in different areas, by using an appropriate lacquer mask, inaccord with typical screen printing techniques. A useable approach wouldbe to provide a full tone print, where the second type of adhesivepattern is to be applied, and a half tone print (half as many dots perunit area) in a region to provide the first type of adhesive pattern. Itis noted that alternate screens from 50 lines per inch can be adaptedand used.

[0029] Still referring to FIG. 1, for the particular embodimentdepicted, the internal field 14 is generally characterized by having awidth inwardly from internal edge 13 b of perimeter adhesive field 13,of at least 0.8 mm., typically at least 3 mm. and typically not morethan 10 mm. Also, preferably, the internal adhesive field 14 ischaracterized by having a greater percentage of surface area havingadhesive coverage, in the region defined by the second (internal)adhesive field 14, than is covered by adhesive in the region defined bythe first (perimeter) adhesive field 13. Most preferably, the amount ofadhesive coverage in the internal adhesive field 14 is at least 80%,preferably at least 90%, typically at least 95%. In typical preferredembodiments, the adhesive coverage in the internal adhesive field 14 iscontinuous. By the term “continuous” in this context, it is not meantthat coverage is necessarily 100%, indeed the adhesive arrangement mayhave various fine pin holes in it. However, when the pattern iscontinuous the adhesive is not in isolated spots, islands or regions,and it typically covers greater than 99.5% of the surface area of thesubstrate 5 defined by the outer borders 16 a, 16 b of the internaladhesive field 14.

[0030] It is noted that a continuous adhesive pattern 14 can be formedby applying the adhesive in a discontinuous dot or printed pattern, by aprocess as characterized and then squeezing down the laminate to spreadthe dots into abutment with adjacent dots, thus forming a continuouspattern. This will be a typical preferred approach, as characterizedbelow.

[0031] Another preferred characteristic of adhesive constructionsaccording to the present invention, is that during manufacture, thetotal amount of adhesive applied in the region that will define theinternal adhesive field 14 is at least 30% greater, per unit area, thanis the total amount of adhesive applied to define the perimeter adhesivefield, per unit area. Most preferably, the amount of adhesiveapplication in the internal adhesive field on a per unit area basis isabout 1.5 to 5 times the amount of adhesive applied in the region thatwill become the outer perimeter adhesive field to the perimeter adhesivefield, on a per unit area basis; typically 1.5-2.5 times. (The ratio forfull tone versus half tone, of course, would be 2:1).

[0032] Thus far the term “adhesive construction” has been used tocharacterize a construction comprising a flexible substrate ascharacterized, with adhesive fields characterized thereon. It is notedthat in some instances herein, the term “adhesive construction” will beutilized to refer to such an arrangement with attached thereto a releaseliner, which can be stripped from the remainder of the adhesiveconstruction, so that a resulting adhesive construction comprising aflexible substrate and adhesive, without a release liner can be appliedfor use.

[0033] Attention is now directed to FIG. 2. In FIG. 2, there is depictedan adhesive construction 30, according to the present invention in theform of a roll for delivery of individual adhesive constructions 1.Machine direction for application is shown by arrow 32. The rollconstruction 30 comprises a continuous strip 31 having secured thereto,in a line, a plurality of spaced covers 33. The covers 33 may begenerally in accord with adhesive constructions 1, and are positioned onthe continuous strip 31 with the adhesive side 6 (FIG. 1) of eachconstruction 1 directed against strip 31 and the non-adhesive side 7facing the viewer.

[0034] For the particular preferred arrangement 30 depicted in FIG. 2,the individual adhesive constructions 1 each comprise a transparentsubstrate 5, so that adhesive fields 13 and 14 are viewable.

[0035] The continuous strip 31 preferably comprises a release liner 34,for example a silicone coated paper, from which the individual adhesiveconstructions 1 can be readily removed in a commercial labeling orapplication process; the silicone coating being at least on the sidefacing the covers 33. Since each of the constructions 1 has a first(perimeter) adhesive field 13 in accord with the preferred descriptionfor adhesive construction 1, stripping of the individual constructions 1from roll construction 30 in a high speed application process isfacilitated. This is in part because the low coverage of adhesive infirst (perimeter) field 13 helps the lead edge 10 d of each adhesiveconstruction 1 to be started to separate from the continuous strip 31 ofrelease liner. Unlike the arrangements of U.S. Pat. Nos. 5,351,426 and4,661,189, in which there is no adhesive along the outer perimeter edge,the presence of at least 30% adhesive coverage in the perimeter field 13facilitates operation by allowing for greater control and labelapplication; and, after the construction 1 is applied to a package orother substrate, perimeter field 13 facilitates the label being retainedin place and not inadvertently lifted and separated from the substrateto which the construction 1 has been applied. This latter advantage,inhibition of unintended or undesired separation from the substrate, isan important advantage of arrangements according to the presentinvention which utilize a perimeter field 13 as the first adhesivefield.

[0036] Still referring to FIG. 2, it is noted that regions 35 on therelease liner 34, between and around individual adhesive constructions1, are generally adhesive-free. This results from a manufacturingoperation in which any adhesive in these regions is stripped from thearrangement, as the roll construction 30 is formed.

[0037] Herein, the term “continuous” when used in reference to labelroll construction 30 is generally meant to a strip 31 which issufficiently long to include at least ten individual adhesiveconstructions 1 thereon, typically oriented in a single column or row.It is noted that typically a roll construction 30 will comprise at least100 to 500 meters of continuous strip 31, with at least 1,000 to 5,000individual constructions 1 in a row thereon. In some instances the rollconstruction 30 will include more than one row or line of constructions1 thereon.

[0038] Attention is now directed to FIG. 3. In FIG. 3, a roll stock 70is shown, from which roll constructions 30, FIG. 2, in accord with thepresent invention can be made, the machine direction for manufacturebeing shown by arrow 71. In general, the roll stock 70 comprises alaminate of two flexible webs 73 and 74 with adhesive 75 positionedtherebetween. The adhesive 75 is provided in a preferred pattern ascharacterized herein, to eventually form the preferred fields 13, 14described above, for individual adhesive constructions 1. In general,web 73 comprises a web of release liner material which, afterappropriate cutting application, will form continuous strip 31, FIG. 2.Web 74, on the other hand, comprises a web of material which, after diecutting, will form the flexible substrates 5 of the various individualadhesive constructions 1.

[0039] For the particular embodiment depicted in FIG. 3, flexible web 74of the roll stock 70 is depicted as a transparent material, allowingviewing of adhesive field 75 and the surface of web 73 thereunder. Tofacilitate understanding, web 74 is fragmented for viewing web 73, atregion 76.

[0040] In FIG. 3, the particular roll stock 70 depicted comprises tworows 77 and 78 of spaced adhesive free areas 79, over which two rows ofindividual adhesive construction 1 will eventually be formed. Thephantom line indicated at 80 depicts a cut line which will eventually bemade through the release liner stock 73, to separate the rows 77, 78 ofroll stock 70 into strips of labels having a single line of labels.Phantom lines 81 indicate where die cutting through the web 74, but notthrough the release liner stock 73, will take place, in order togenerate the individual substrates 5, FIG. 1. The die cutting operationwill be described in greater detail, below. The particular roll stock 70depicted includes narrow adhesive-free strips 82 along each side edge83, to facilitate handling.

[0041] Still referring to FIG. 3, roll stock 70 includes two types ofadhesive fields thereon. The first type of adhesive field is indicatedgenerally at 85. A portion of field 85 comprises an adhesive fieldwhich, in a final label product, will generate first (perimeter) fields13, FIG. 1. Thus, the first type of adhesive field 85 preferablycomprises adhesive coverage of between 30% and 80% coverage of thesurface area defined by its borders 85 a and 85 b, most preferablycoverage as defined for FIG. 1.

[0042] The second type of adhesive field is indicated at 86 and, in thefinal adhesive constructions 1, will form second (internal) fields 14,FIG. 1. Thus, preferably the second type of adhesive field 86 comprisesat least 80%, and most preferably continuous adhesive coverage in theregions defined by borders 86 a and 86 b.

[0043] Still referring to FIG. 3, it is again noted that the roll stock70 includes a plurality of spaced adhesive-free regions 79 in whichthere is no adhesive between the two webs 73, 74. Regions 79, in thefinal label roll construction 30, FIG. 2, form unsealed regions 17.

[0044] Still referring to FIG. 3, it is noted that all die cut lines 81are positioned in overlap with adhesive fields 85 of the first type.That is, during the die cutting operation to form the individualconstructions, covers, components for labels, the die cutting ispreferably through web 74 in overlap with regions where, between the web74 and the web 73, there is positioned adhesive field 85 of the firsttype. As a result, the die cutting operation avoids die cuts in regionsin which there is a higher percentage of adhesive such as is found inadhesive fields of the second type.

[0045] By the term “overlap” in this context, it is meant that thestrike of the die cut from the viewpoint of FIG. 3 through web 74 in aportion directly above region 85.

[0046] After the die cutting operation, once waste material from web 74is stripped away, the resulting adhesive constructions 1 or covers 33,FIG. 2, will have a perimeter edge along which there is a perimeteradhesive field of the type indicated at 13, FIG. 1. It is noted that ingeneral, the material selected for the adhesive, the release liner 73and the substrate web 74 will be such that adherence of the adhesive tothe substrate 74 material is greater than the adherence of the adhesiveto the release liner 73. One result of this is that when waste or scrapmaterial from web 74 is stripped away after die cutting, the regions ofrelease liner 73 which remain and which are not covered by theindividual die cut adhesive constructions 1, are adhesive-free.

[0047] In a typical cutting operation, then, die cutting to formindividual adhesive construction, occurs in the regions indicated atlines 81 to define a die cut pattern or perimeter pattern circumscribingindividual labels or covers. The resulting waste material betweenadhesive construction or covers is stripped from the roll stock 70,leaving continuous web 73 intact with a plurality of spaced adhesiveconstructions 1 is secured thereto. Web 73 can be cut, into strips, bycutting along line 80 between the rows of adhesive constructions, toresult in two one lane roll constructions 30 each of which is as shownin FIG. 2. This final cutting operation, to form the individual rolls30, would be through adhesive-free regions as a result of the strippingof waste material of layer 74 from layer 73, after die cutting.

[0048] In general, roll stock 70 in accord with FIG. 3, is readilymanufactured by a process of applying an appropriate adhesive pattern toone of the two webs 73, 74, and then bringing the two webs together in acontinuous operation. Various methods can be utilized to apply theadhesive, typically dot or spot printing being preferred. With dot orspot printing, variations in the amount of adhesive applied in variouslocations, to generate the two types of adhesive fields 85, 86characterized, can be readily conducted. In a typical operation, theadhesive is applied in a dot or spot pattern on one or the other of thetwo webs 73, 74, prior to the webs being brought together to form thelaminate 70. A transfer printing process can be utilized.

[0049] When the webs are brought together, typically they are squeezedtogether in a nip or bite between rollers. In a typical printingoperation, a higher concentration of dots or spots is placed in a regionwhich will become the inner portion 14, with a continuous adhesivepattern. Even though the spots in this region may be created in anisolated continuous pattern, as a result of the squeezing process thespots in this region will spread and join with one another, to form thecontinuous pattern. In the region which will become the first (outerperimeter) adhesive pattern 13, however, typically the spot pattern issufficiently low in population, so that even after the squeezingoperation a discontinuous pattern of adhesive still results. This can bereadily accomplished by using 30%-60% (by wt.) of adhesive, per unitarea, of adhesive for the region to become the discontinuous pattern,than is used in the region to become the continuous pattern. Typically,dots applied at 20-100 dots/inch, will be convenient to generate suchpatterns. A usable printing process is screen printing using a screen at50 lines/inch, with half tone printing for pattern 13, and full tone forpattern 14.

[0050] In general, for the preferred arrangements of FIGS. 1-3, theadhesive patterns are defined with respect to perimeter patterns andinner patterns. It is noted that in general the principles relate toapplication of at least two different patterns of adhesives on asubstrate, generally referenced as a first pattern and as a secondpattern. The first pattern would in general define at least 10 sq. mm.(typically at least 30 sq. mm.) of area with a discontinuous adhesivepattern covering no more than 80% of the defined area, preferably of nomore than 70%; and, the second adhesive area would define at least 10sq. mm. (typically at least 30 sq. mm.) with adhesive covering at least80%, preferably at least 90%, typically at least 95% with adhesive, mostpreferably in a continuous pattern covering at least 99.5% of the area.For such arrangements, preferably the second area of adhesive comprisesat least 30%, per unit area, more adhesive than is found in the firstadhesive region. Of course, in preferred constructions such as thosedescribed, the first adhesive region is a perimeter adhesive region andthe second adhesive region is an inner adhesive region. However, fromthe example provided, it will be understood that alternate arrangementsof the two adhesive patterns are available, and, indeed, there may bestill further adhesive regions provided on the substrate. In addition,the first adhesive region could be broken into more than one separatearea, each of which has a minimum area of at least 10 sq. mm.; and/orthe second region could be broken into more than one region, each ofwhich has a minimum area of at least 10 sq. mm.

[0051] Preferred Materials

[0052] A variety of materials can be utilized in arrangements accordingto the present invention. Typical preferred materials would be asfollows:

[0053] (1) for the label substrate, a usable material is, for example,clear 2 mm. biaxially oriented polypropylene (BOPP), for example, asavailable from a variety of films companies such as Armstrong SpecialtyFilms, Inc., Mukwongo, Wis., 53149;

[0054] (2) for the release liner, a utilizable material is 43 pounddiversified Kraft paper with a silicone release coating, such as isavailable from the Siltech Division of Technicote, Co., Miamisburg, Ohio45342.

[0055] (3) for the pressure sensitive adhesive a variety of commerciallyavailable pressure sensitive adhesives can be used, with the specificchoice generally being dependent upon the desired conditions ofapplication. Usable pressure sensitive adhesives are available, forexample, from H. B. Fuller, St. Paul, Minn.; Ashland Petroleum,Columbus, Ohio 43216; and, Hartland Adhesives of New Berlin, Wis.

[0056] Typically, the amount of adhesive applied during the printingoperation in the regions that will form the first (perimeter) fields 13,FIG. 1, is about 35-65% (usually 40-60%) of the amount of adhesiveapplied in the regions which will provide the internal adhesive field14, FIG. 1. The wt. % given is meant to refer to the weight of adhesiveapplied per unit area.

[0057] Preferred Configurations and Dimensions

[0058] While a wide variety of configurations and dimensions may beutilized in arrangements according to the present invention, it isforeseen that in typical applications, the adhesive constructions willbe parallelograms, typically rectangles or squares. In general, it isanticipated that in typical preferred constructions the perimeteradhesive fields will be of even width around the perimeter, typicallyabout 1 to 10 mm. wide; and, the internal adhesive field 14 will be aframed construction having an even width around the frame, typicallyabout 10 to 40 mm. wide. It is foreseen that in general, the centralregion of the label will be a region that has no adhesive thereon, andwill typically comprise at least about 30% and generally about 40% to80% of the total perimeter area of the label or cover; the term“perimeter area” in this context, refers to label area as defined by theouter perimeter of the label or cover.

[0059] The above specification, examples and data provide a generaldescription of the manufacture and use of the composition of theinvention. Many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention.

What is claimed is:
 1. An adhesive construction comprising: (a) aflexible substrate defining a having a first side; (b) a first adhesivefield comprising pressure sensitive adhesive; (i) the first adhesivefield being a discontinuous pattern of adhesive with adhesive coveringno more than 80% of an area of a portion of the first side of theflexible substrate defined by the first adhesive field; the area of aportion of the first side of the flexible substrate defined by the firstadhesive field being at least 10 sq. mm. and, (c) a second adhesivefield comprising pressure sensitive adhesive; (ii) the second adhesivefield covering at least 90% of an area of a portion of the first side ofthe flexible substrate defined by the second adhesive field; the area ofa portion of the first side of the flexible substrate defined by thesecond adhesive field being at least 10 sq. mm.
 2. An adhesiveconstruction according to claim 1 wherein: (a) the flexible substratedefines an outer perimeter edge; (b) the first adhesive field comprisesan outer perimeter adhesive field positioned on the flexible substratefirst side and adjacent the outer perimeter edge; (i) the outerperimeter adhesive field having a width, in direction inwardly from theperimeter edge, of at least 0.8 mm.; and, (c) the second adhesive fieldcomprises an inner adhesive field spaced from the outer perimeter edgeand completely surrounded by the outer perimeter adhesive field; (i) theinner adhesive field comprising adhesive covering at least 95% of anarea of the portion of the first side of the flexible substrate definedby the inner adhesive field.
 3. An adhesive construction according toclaim 2 wherein: (a) the inner adhesive field comprises a continuousadhesive field over the area of the portion of the first side of theflexible substrate defined by the inner adhesive field.
 4. An adhesiveconstruction according to claim 3 including: (a) an adhesive-free regionon the first side of the flexible substrate; (i) the adhesive-freeregion being completely surrounded by the inner adhesive field.
 5. Anadhesive construction according to claim 4 wherein: (a) theadhesive-free region comprises at least 40% of a perimeter area definedby the flexible substrate outer perimeter edge.
 6. An adhesiveconstruction according to claim 5 wherein: (a) the outer perimeter edgedefines a rectangular pattern.
 7. An adhesive construction according toclaim 6 wherein: (a) the adhesive-free region of the flexible substrateis transparent.
 8. An adhesive construction according to claim 7wherein: (a) the outer perimeter adhesive field defines a rectangularframe.
 9. An adhesive construction according to claim 8 wherein: (a) theinner adhesive field defines a rectangular frame.
 10. An adhesiveconstruction according to claim 2 wherein: (a) the outer perimeter edgehas no segment of extension of greater than 8 mm., at which there is notadhesive on the substrate first side and immediately adjacent the outerperimeter edge.
 11. An adhesive construction according to claim 11wherein: (a) the outer perimeter edge has no segment of extension ofgreater than 5 mm., at which there is not adhesive on the substratefirst side and immediately adjacent the outer perimeter edge.
 12. Anadhesive construction according to claim 1 including: (a) a releaseliner to which the flexible substrate is secured by the first adhesivefield and the second adhesive field.
 13. A roll of adhesiveconstructions; the roll comprising: (a) an extension of release liner;(b) at least 10 spaced adhesive constructions secured to the extensionof release liner; each adhesive construction comprising: (i) a flexiblesubstrate having a first side; (ii) a first adhesive field comprisingpressure sensitive adhesive; (A) the first adhesive field being adiscontinuous pattern of adhesive with adhesive covering no more than80% of an area of a portion of the first site of the flexible substratedefined by the first adhesive field; the area of a portion of the firstside of the flexible substrate defined by the first adhesive field beingat least 10 sq. mm.; and, (iii) a second adhesive field comprisingpressure sensitive adhesive; (A) the second adhesive field covering atleast 90% of an area of a portion of the first side of the flexiblesubstrate defined by the second adhesive field; the area of a portion ofthe first side of the flexible substrate defined by the second adhesivefield being at least 10 sq. mm.
 14. A roll of adhesive constructionsaccording to claim 13 wherein: (a) the flexible substrate of eachadhesive construction defines an outer perimeter edge; (b) the firstadhesive field of each adhesive construction comprises an outerperimeter adhesive field positioned on the associated flexible substratefirst side and adjacent the outer perimeter edge; (i) each outerperimeter adhesive field having a width, in direction inwardly from anassociated perimeter edge, of at least 0.8 mm.; and, (c) the secondadhesive field of each adhesive construction comprises an inner adhesivefield spaced from an associated outer perimeter edge and completelysurrounded by an associated outer perimeter adhesive field; (i) eachinner adhesive field comprising adhesive covering at least 95% of anarea of the portion of the first side of an associated flexiblesubstrate defined by the inner adhesive field.
 15. A roll of adhesiveconstructions according to claim 14 wherein: (a) each inner adhesivefield comprises a continuous adhesive covering over the area of anassociated portion of the first side of the flexible substrate definedby that inner adhesive field.
 16. A method of preparing an adhesiveconstruction; said method including the steps of: (a) preparing alaminate stock comprising a release liner layer secured to a flexiblesubstrate layer, with an adhesive pattern of pressure sensitive adhesivetherebetween; (i) the adhesive pattern defining: (A) a first adhesivefield comprising a discontinuous pattern of adhesive with the adhesivecovering no more than 80% of an area of a portion of a side of theflexible substrate layer defined by the first adhesive field; and, (B) asecond adhesive field comprising adhesive covering at least 90% of anarea of a portion of a side of the flexible substrate layer defined bythe second adhesive field; (b) die cutting the laminate stock by cuttinga die cut perimeter pattern completely through the flexible substratelayer but not completely through the release liner layer; (i) theperimeter pattern being die cut through a region in overlap withadhesive in the first adhesive field and surrounding adhesive in thesecond adhesive field, (ii) the step of die cutting defining: (A) wasteflexible substrate layer outside of the die cut perimeter pattern; and,(B) a die cut adhesive construction within the die cut perimeterpattern; and, (c) stripping the waste flexible substrate from thelaminate stock, while leaving at least one die cut adhesive constructionon the release liner layer.
 17. A method according to claim 16 wherein:(a) the second adhesive field is an inner adhesive field comprisingadhesive covering at least 95% of the area of the portion of theflexible substrate layer defined by the second adhesive field; and, (b)the first adhesive field is an outer perimeter adhesive field completelysurrounding the first inner adhesive field.
 18. A method according toclaim 17 wherein: (a) the adhesive pattern defines a first adhesive-freeregion completely surrounded by the second adhesive field.
 19. A methodaccording to claim 18 wherein: (a) said step of die cutting comprisescutting to form a die cut perimeter pattern spaced at least 0.8 mm. fromthe inner adhesive field completely around the first inner adhesivefield.
 20. A method according to claim 19 wherein: (a) said methodcomprises a process of generating a series of spaced adhesiveconstructions adhered to the release liner; (i) each one of the seriesof spaced adhesive constructions comprising: (A) a flexible substratedefining an outer perimeter edge; the flexible substrate having a firstside; (B) an outer perimeter adhesive field adjacent the outer perimeteredge; (I) the outer perimeter adhesive field having a width, indirection inwardly from the perimeter edge, of at least 0.8 mm.; (II)the outer perimeter adhesive field being a discontinuous pattern ofadhesive with adhesive covering no more than 80% of an area of a portionof the first side of the flexible substrate defined by the outerperimeter adhesive field; and, (C) an inner adhesive field spaced fromthe outer perimeter edge and completely surrounded by the outerperimeter adhesive field; (I) the inner adhesive field comprisingadhesive covering at least 95% of an area of a portion of the first sideof the flexible substrate defined by the inner adhesive field; and, (ii)each one of the series of spaced adhesive constructions being formed ina die cutting operation which involves cutting die cut perimeterpatterns each of which is: (A) completely through the flexible substratelayer but not completely through the release lines layer; and, (B) cutthrough a region in overlap with adhesive in an outer perimeter adhesivefield and surrounding and not in overlap with adhesive in an inneradhesive field.